High Power Output Electric Brushless Outrunner Stator Lamination Supplier
High Power Output Electric Brushless Outrunner – Stator Laminations for Maximum Power Density
Need more thrust? Motor struggling under heavy loads? Heat limiting your power output? A high power output electric brushless outrunner demands stator laminations that can handle extreme magnetic flux, high currents, and sustained thermal stress. Reenives delivers precision-engineered stator laminations for high-power outrunner motors with 0.2mm ultra-thin silicon steel, burr height < 0.03mm, and epoxy coating—reducing core loss by up to 30%, maximizing power density, and enabling sustained high-output performance for heavy-lift drones, eVTOL, and industrial propulsion systems.
- • What Is a High Power Output Electric Brushless Outrunner?
- • Classification of High Power Outrunner Stator Laminations
- • Technical Specifications & Verified Data
- • Applications: Heavy-Lift Drones, eVTOL, Industrial & More
- • 6-Step Engineering Selection Guide for High Power Outrunner Stator Laminations
- • FAQ: High Power Outrunner Stator Lamination Technical Questions
- • Why Reenives – High Power Output Electric Brushless Outrunner Stator Lamination Supplier
- • Dongguan Runlu Motor Technology Co., Ltd.
What Is a High Power Output Electric Brushless Outrunner?
A high power output electric brushless outrunner is a brushless DC motor where the rotor (with permanent magnets) rotates on the outside of the stator, while the stator core remains stationary at the center. This "outrunner" configuration allows for larger diameter rotors, which translates to higher torque at lower RPM—ideal for direct-drive propeller applications in drones, eVTOL, and electric aviation.
Key characteristics of high power outrunner motors:
- High torque density – Large rotor diameter provides mechanical advantage
- Direct drive – No gearbox needed; propeller mounts directly to rotor
- High power output – Capable of 5–50+ kW continuous power
- High thermal stress – Demands stator laminations with low core loss and good heat dissipation
- Multi-pole configurations – 24N22P, 36N30P, and custom designs
The stator lamination is the critical component that enables high power output. For high-power outrunner motors, stator laminations must:
- Minimize core loss to reduce heat generation at high power
- Provide high saturation flux density for maximum torque
- Maintain structural integrity under thermal and mechanical stress
- Ensure precise geometry for consistent air gap and smooth operation
ⓘ High power insight: "For a high power output electric brushless outrunner, the stator lamination is the foundation of power density. A 30% reduction in core loss translates to 15–20% higher continuous power output before thermal limits are reached."
Reenives manufactures precision stator laminations for high power outrunner motors using imported 0.2mm silicon steel, progressive stamping dies, and automated epoxy powder coating—enabling maximum power density for demanding UAV, eVTOL, and industrial applications.
Classification of High Power Outrunner Stator Laminations
Reenives supplies stator laminations across four primary series for high power outrunner motors, tailored to power class and application:
| Series | Power Range | Stator OD (mm) | Slot/Pole Configuration | Lamination Thickness | Best For |
|---|---|---|---|---|---|
| Series A – High Power (5–15kW) | 5–15kW | 60–100mm | 24N22P | 0.20mm | Heavy-lift drones, cargo UAV |
| Series B – Extreme Power (15–35kW) | 15–35kW | 80–140mm | 36N30P | 0.20mm | eVTOL, air taxis, large cargo |
| Series C – Ultra Power (35–50+ kW) | 35–50+ kW | 120–200mm | 48N40P, custom | 0.20mm | Electric aviation, industrial propulsion |
| Series D – Custom OEM | Any | Any | Any slot/pole | 0.15–0.35mm | Specialized high-power designs |
High power outrunner stator laminations are characterized by:
- Large diameter – 60–200mm to accommodate high torque requirements
- Multi-pole configurations – 24N22P, 36N30P, 48N40P for smooth torque at low RPM
- Thin laminations – 0.20mm to minimize core loss at high electrical frequencies
- Robust construction – High stacking factor and strong interlock for structural integrity
Technical Specifications & Verified Data
All performance data below is derived from Reenives in-house laboratory testing (IEC 60404-2), third-party validation, and peer-reviewed high-power motor research.
| Parameter | Value / Range (Reenives Standard) | Test Standard / Source |
|---|---|---|
| Stator Outer Diameter | 60–200mm (customizable) | CMM / optical comparator |
| Lamination Material | 35PN210, 35PN250 (Nippon Steel / Baowu) | Material certificates |
| Lamination Thickness | 0.20mm (standard), 0.15mm (ultra-high freq) | Micrometer / IEC 60404-2 |
| Core Loss @ 1.0T, 400Hz | ≤ 8.5 W/kg (0.20mm) — 30% lower than 0.35mm | IEC 60404-2 / CMQIC Report |
| Saturation Flux Density Bs | 1.68 – 1.72 T | Epstein frame test |
| Burr Height (max) | < 0.03mm | Optical measurement |
| Epoxy Coating Thickness | 30–60 µm, dielectric > 2.5 kV | ASTM D149 |
| Stacking Factor | ≥ 97.5% | Weight method |
| Concentricity Tolerance | ±0.01mm – ±0.015mm | CMM measurement |
| Slot/Pole Configurations | 24N22P, 36N30P, 48N40P, custom | Reenives design standards |
| Typical Motor Efficiency | 92–96% (with optimized stator) | IEEE Xplore / FEM simulation |
| Power Density Improvement | 15–20% (vs. standard 0.35mm stator) | Reenives R&D / thermal analysis |
🔬 Data Source: Reenives R&D Report 2024-Q4 + CMQIC Test Report + IEC 60404-2 standard + IEEE Xplore high-power motor studies.
Applications: Heavy-Lift Drones, eVTOL, Industrial & More
High power output electric brushless outrunner motors with precision stator laminations power a wide range of demanding applications:
| Application | Power Range | Stator Requirements | Performance Priorities |
|---|---|---|---|
| Heavy-Lift Cargo Drones | 5–15kW | 24N22P, 0.20mm, epoxy coated | High thrust, efficiency, reliability |
| eVTOL / Air Taxis | 15–35kW | 36N30P, 0.20mm, high thermal stability | Safety, redundancy, high continuous power |
| Electric Aviation | 35–50+ kW | 48N40P, custom, ultra-low core loss | Maximum power density, efficiency, reliability |
| Industrial Propulsion | 10–50kW | Custom configurations | Durability, thermal management, continuous duty |
| Agricultural UAVs | 5–15kW | 24N22P, corrosion-resistant coating | Dust/chemical resistance, heavy payload |
| Marine Propulsion | 10–30kW | Custom, corrosion-resistant | Saltwater resistance, reliability |
"For high power output electric brushless outrunner motors, the stator lamination is the enabler of power density. Precision laminations allow motors to push thermal limits and deliver sustained high power."
6-Step Engineering Selection Guide for High Power Outrunner Stator Laminations
For UAV motor designers and procurement engineers, selecting the optimal stator lamination for high power output electric brushless outrunner motors requires systematic evaluation. Here is a practical 6-step framework:
- Define Power & Torque Requirements – Identify your motor's performance targets:
- Continuous power: 5kW, 15kW, 35kW, 50+ kW?
- Peak power: How much overload capacity is needed?
- Torque requirements: Direct drive or geared?
- Operating RPM range: Low-speed high-torque or high-speed?
- Select Stator Outer Diameter – Match motor size to power class:
- 60–80mm: 5–15kW, heavy-lift drones
- 80–120mm: 15–35kW, eVTOL, large cargo
- 120–200mm: 35–50+ kW, electric aviation, industrial
- Choose Slot/Pole Configuration – Critical for torque and efficiency:
- 24N22P: High torque, smooth operation, 5–15kW range
- 36N30P: Maximum torque density, 15–35kW range
- 48N40P: Ultra-smooth, high power, 35–50+ kW
- Custom configurations for specialized applications
- Specify Lamination Thickness – Thinner laminations reduce core loss at high frequencies:
- 0.20mm: Optimal for most high-power outrunner applications
- 0.15mm: Ultra-high-frequency operation, extreme efficiency
- 0.35mm: Not recommended for high-power drone/eVTOL motors
ⓘ "0.20mm laminations reduce core loss by approximately 30% compared to 0.35mm—enabling 15–20% higher continuous power output."
- Verify Thermal & Structural Requirements – High-power motors demand:
- High stacking factor (≥ 97.5%) for maximum magnetic material
- Epoxy coating (30–60µm, Class H 180°C) for thermal durability
- Strong interlock or welding for structural integrity
- Precision concentricity (≤ ±0.01mm) for consistent air gap
- Choose a Specialist High-Power Stator Supplier – Evaluate expertise:
- Experience with high-power outrunner motor stators (60–200mm OD)
- Ultra-thin lamination capability (0.20mm and below)
- Precision stamping: burr < 0.03mm, concentricity ±0.01mm
- Multi-pole configuration expertise (24N22P, 36N30P, 48N40P)
- Epoxy coating for high-power thermal environments
- Material certificates and third-party test reports
- Proven track record with eVTOL and high-power UAV manufacturers
- Engineering support for high-power motor optimization
FAQ: High Power Outrunner Stator Lamination Technical Questions
For high power outrunner motors, the optimal stator lamination features: 0.20mm (or 0.15mm for extreme applications) silicon steel, 24N22P or 36N30P slot/pole configurations, burr height < 0.03mm, epoxy coating (30–60µm, Class H 180°C), and stacking factor ≥ 97.5%. These parameters minimize core loss at high electrical frequencies, maximize power density, and ensure thermal stability under sustained high-power operation. Reenives specializes in these high-power outrunner stator laminations.
Lamination thickness directly impacts core loss in high-power motors operating at high electrical frequencies (up to 40 kHz PWM). 0.20mm laminations achieve core loss ≤ 8.5 W/kg at 400Hz—approximately 30% lower than 0.35mm material. For high power outrunner motors, this reduction in core loss translates to: (1) 15–20% higher continuous power output before thermal limits, (2) cooler operation, (3) higher efficiency (92–96%), and (4) reduced cooling system requirements. 0.15mm laminations provide ultimate performance for extreme applications.
For high power outrunner motors, 24N22P (24-slot stator, 22-pole rotor) is a common configuration for 5–15kW applications, offering excellent torque density and smooth operation. For higher power ranges (15–35kW), 36N30P is preferred, providing maximum torque density and low cogging torque. For extreme power (35–50+ kW), 48N40P or custom configurations are used. The optimal configuration depends on power level, RPM range, and application requirements. Reenives supports all these configurations with custom tooling.
Epoxy powder coating provides three critical functions for high power outrunner stators: (1) electrical insulation between laminations to minimize eddy currents and prevent interlaminar shorts—critical at high current densities, (2) thermal durability up to 180°C (Class H) to withstand the extreme heat generated during sustained high-power operation, and (3) corrosion resistance for outdoor UAV and marine applications. The coating thickness (30–60µm) is optimized with dielectric strength exceeding 2.5 kV for reliable high-voltage operation.
Burr height in stator laminations must be maintained below 0.03mm for high power outrunner motors because excessive burrs can: (1) damage enamel insulation on thick copper windings during assembly—causing short circuits at high current, (2) create localized magnetic saturation points that reduce torque output, (3) increase core loss through eddy current concentration, and (4) reduce motor reliability—critical for eVTOL and aviation applications where motor failure is catastrophic. Reenives maintains burr height < 0.03mm through precision progressive stamping dies.
With optimized stator laminations (0.20mm, 24N22P/36N30P, epoxy coated), high power outrunner motors can deliver: (1) 5–15kW continuous power for heavy-lift drones, (2) 15–35kW for eVTOL and air taxi applications, (3) 35–50+ kW for electric aviation and industrial propulsion, and (4) peak power up to 2x continuous for short durations. The exact power output depends on stator size, cooling system, and electrical design. Reenives stator laminations are engineered to maximize the power density of your motor design.
Yes. Reenives supports full customization of high power outrunner stator laminations including: stator outer diameter (60–200mm), lamination thickness (0.15–0.20mm), slot/pole configurations (24N22P, 36N30P, 48N40P, custom), stacking height, material grade (35PN210, 35PN250), and epoxy coating specifications. Private mould development is available for high-volume OEM projects with exclusive design rights—from heavy-lift drones to electric aviation propulsion systems.
Why Reenives – High Power Output Electric Brushless Outrunner Stator Lamination Supplier
Reenives has earned its reputation as a specialist High Power Output Electric Brushless Outrunner Stator Lamination Supplier by combining advanced manufacturing technology with deep expertise in high-power motor applications.
Our Advantages — Power Density Specialists
- ✅ Ultra-Thin Silicon Steel: 0.20mm laminations reduce core loss by up to 30%—enabling 15–20% higher continuous power output
- ✅ Large Diameter Capability: Stator OD up to 200mm for high-power outrunner motors
- ✅ Multi-Pole Expertise: 24N22P, 36N30P, 48N40P, and custom configurations
- ✅ Precision Stamping: Burr height < 0.03mm, concentricity ±0.01mm, stacking factor ≥ 97.5%
- ✅ Epoxy Coating: 30–60µm, Class H 180°C, dielectric > 2.5 kV
- ✅ Full Customization: Private mould development for exclusive high-power designs
- ✅ Trusted Quality Control: IEC 60404-2 testing, CMQIC verification, material certificates
- ✅ Global Export: Complete export qualifications with worldwide shipping
- ✅ Proven Track Record: 4 years experience, 1,000+ enterprise clients, 100+ R&D patents
⚡ Our high power promise: Stator laminations that maximize power density and thermal limits. Consistent quality that eliminates rework. Engineering support that optimizes your high-power motor design. That's why Reenives is the trusted high power outrunner stator lamination supplier.
⚡ Ready to maximize your outrunner motor's power output with precision stator laminations?
Contact Reenives today for engineering consultation, OEM samples, and competitive bulk pricing.
📱 WhatsApp: +86-13377741885
Dongguan Runlu Motor Technology Co., Ltd.
Reenives — Professional Drone Stator Core Manufacturer
Founded in 2022, Reenives has rapidly grown into a trusted high power outrunner stator lamination supplier and stator core manufacturer for the global UAV, eVTOL, and industrial motor markets.
Independent R&D Technology · Imported stamping & epoxy powder coating production lines · Dust-free workshops · 4 years of manufacturing experience · Solved high-power stator challenges for 1,000+ enterprises worldwide—including leading eVTOL and heavy-lift drone manufacturers.
From production to sales, we support bulk purchasing, private mould development, and sample making. We provide tailor-made solutions for your specific high-power motor production scenarios—with competitive pricing, consistent quality, and reliable on-time delivery.
🌐 www.reenives-bldcmotor.com | 📧 linda_reenives@163.com | 📱 +86-13377741885
✈️ Global high-power motor manufacturers welcome — consult, visit the factory, or request free samples today!
Reenives — High Power Output Electric Brushless Outrunner Stator Lamination Supplier
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